FEATURES

• Various temperature settings
• Miniature size
• Current rating: 15 Amp/125
Vac, 10 Amp/250 Vac
• Economical
• Accurate
• Large inventory; same day
shipping
• Various mounting options
The Thermal DF Series Thermal Cutoffs are single action devices that open when
a preset temperature is reached. They do not reset. The active component of a ther-
mal cutoff is an electrically insulated thermal pellet. This pellet holds a spring loaded
contact against a fixed contact under normal operating temperatures. (See Fig. 1)
When the preset temperature of the cutoff is reached, the pellet liquifies, the springs
relax, and the spring loaded contact is moved away from the fixed contact, opening the
circuit. (See Fig. 2) The DF Series is the right choice for applications requiring an inex-
pensive limit protector with 15A capability.

APPLICATIONS
Thermal cutoffs are widely
used to prevent damage
from overheating in electrical
products
• APPLIANCES - space (Fig. 1) CLOSED
heaters, irons, stoves,
electric blankets, hair
dryers, clothes dryers,
cookers, toaster ovens,
crock pots, mixers, toasters,
microwave ovens, etc.
(Fig. 2) OPEN
• MOTORS - air conditioners, DF Series
copiers, fans, washing
machines, compressors,
etc.
• ELECTRONICS - TVs,
stereos, tape recorders,
video recorders, fluorescent
A B C
lamps, transformers,
D
computers, surge suppres-
E
sors, telecommunication
equipment, etc.

Standard Dimensions (mm)

A B C D E
25.4±1 10.5±0.5 35±1 ø1±0.05 ø4.0±0.1
Custom lead lengths are available.

www.thermtrol.com
E-mail: sales@thermtrol.com 8914 Pleasantwood Ave., N.W. • P.O. Box 2501 • North Canton, OH 44720 • (330) 497-4148 • Fax (330) 497-4189
Precautions When Using Handling and Installation
Thermal Cutoffs Instructions
The following information describes the correct methods of
using thermal cutoffs to insure proper and safe performance. To When using thermal cutoffs, considerable caution should be exer-
achieve the full use and capacity of a thermal cutoff, it is necessary cised as follows:
for the customer to exercise proper storage and execute appropriate
circuit design, proper installation, and adequate testing. Thermtrol A. Installation
Corporation does not assume responsibility for problems which occur • Mount the thermal cutoff in a location where uniform radiation of
as a result of improper storage and installation, or inappropriate heat is sustained over the body of the unit.
circuit design, evaluations or tests. • Keep the leads as long as possible to maximize the area of expo-
• Do not use thermal cutoffs for purposes other than for what they are sure to heat.
intended. Thermal cutoffs operate only when they sense an ambient • Place and connect the thermal cutoff in a manner so that no
temperature greater than the factory pre-set temperature. They have external mechanical force will be applied to the body and/or leads of
no ability to function by current overload and are not current the thermal cutoff.
limiting devices. • Allow adequate space for mounting the thermal cutoff.
• Do not use thermal cutoffs in equipment, appliances or devices
intended to be used in the aerospace industry, aviation, nuclear B. Lead Bending
power generation systems, life support systems, engine control • When bending a lead, bend at a location 5mm minimum from the
systems, or safety control systems for transportation. Thermal cutoffs body of the thermal cutoff.
are applicable for electrical household devices, appliances and • Take caution not to damage either the thermal cutoff body or the lead.
electronics. Other applications include: office automation equipment, • Keep the thermal cutoff body free from any push, pull or twist force.
audiovisual equipment, communication systems, measuring instru-
ments and specific transportation systems. C. Soldering
• Do not use thermal cutoffs in applications exceeding the listed NOTE: The special sealant joining the lead wires to the case will
ratings in the specification chart. soften during soldering. Care must be taken to not move the leads
• Do not use thermal cutoffs in a liquid, in a corrosive atmosphere or body during the soldering process as the softened joints could
such as sulfurous gas, or in a high humidity environment. shift and become disconnected. The sealant will resume its initial
• Customers shall choose the thermal cutoff appropriate for the strength after cooling.
application and determine the proper mounting position and/or • Minimize the conduction of excessive heat to the thermal cutoff
method. To judge whether the selected thermal cutoff and chosen body when soldering.
position and method of mounting is suitable for the final application, • Maximum soldering time is shown in table above.
we recommend that the customer fully test and evaluate the unit in an • Solder 20 mm minimum from the thermal cutoff body.
environment that duplicates the final application as closely as • During soldering, both the thermal cutoff body and leads should be
possible. This includes mounting and securing the thermal cutoff free of any push, pull or twist force.
identically to the method that will be used in production. • After soldering, allow the thermal cutoff to cool for 30
seconds minimum without moving it.
Electrical Ratings and Selected Agency Approvals
Functioning c Maximum soldering time at solder bath
Part Temperature (°C) TH TM 15 Amp/125Vac 15 Amp/125Vac 10 Amp/250Vac temperature of 300°C
Number Tol: +0°C/-4°C (°C) (°C) 10 Amp/250Vac 10 Amp/250Vac
DF66S 66 42 130 ● ● ● Opening Temp. Max. Soldering Time
DF72S 72 50 110 ● ● ● Under 120° C 2 seconds
DF77S 77 55 130 ● ● ● Over 120° C 3 seconds
DF84S 84 60 114 ● ● ●
DF91S 91 67 121 ● ● ●
DF98S 98 76 130 ● ● ●
DF100S 100 78 135 ● ● ●
DF104S 104 80 150 ● ● ●
DF110S 110 88 140 ● ● ●
Terminology:
DF119S 119 95 170 ● ● ● Functioning Temperature (TF)
DF128S 128 106 155 ● ● ● The temperature at which a thermal cutoff changes its state of
DF139S 139 117 170 ● ● ● conductivity to open a circuit with detection current of 10mA or less
DF141S 141 117 171 ● ● ● as the only load. The temperature tolerance for the UL and CSA
DF144S 144 120 240 ● ● ● standard is +0°C / -10°C.
DF152S 152 128 175 ● ● ● Holding Temperature (TH)
DF170S 170 146 190 ● ● ● The maximum temperature at which a thermal cutoff can be main-
DF184S 184 160 214 ● ❍ ● tained while conducting rated current for 168 hrs. without functioning.
DF192S 192 167 210 ● ❍ *●*
DF198S 198 170 244 ❍ ❍ ❍ Maximum Temperature (TM)
The maximum temperature at which mechanical and electrical prop-
DF216S 216 186 241 ❍ ❍ *●*
erties of a thermal cutoff can be maintained for 10 minutes without
DF228S 228 193 248 ● ❍ *●* resuming conductivity after functioning.
DF240S 240 200 260 ● ❍ *●*
UL/ CUL: E117626 ● Approved ❍ Pending
VDE: 115369, *116219
12/13